wall TW56 I n s u l a t i o n INSULATED PLASTERBOARD FOR MECHANICALLY FIXED DRY LINING Low Energy Low Carbon Buildings

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1 I n s u l a t i o n CI/Sfb (21.9) Rn7 M2 First Issue July 2012 wall TW56 INSULATED PLASTERBOARD FOR MECHANICALLY FIXED DRY LINING High performance rigid thermoset insulation thermal conductivity W/m.K Insulation, dry lining and vapour control in one board Allows quick response heating Unaffected by air infiltration Resistant to the passage of water vapour Easy to handle and install Ideal for new build and refurbishment Non-deleterious material Manufactured with a blowing agent that has zero ODP and low GWP Low Energy Low Carbon Buildings

2 Design Considerations Responsible Sorcing Kingspan Thermawall TW56 Insulated Plasterboard produced at Kingspan Insulation's Castleblayney manufacturing facility is manufactured under a management system certified to BS / I.S. EN ISO 14001: The principle polymer component of the product produced at this facility is also manufactured under a management system certified to BS EN ISO 14001: NB The above information is correct at the time of writing. Please confirm at the point of need by contacting Kingspan Insulation s Technical Services Department (see rear cover), from which copies of Kingspan Insulation and its suppliers ISO certificates can be obtained along with confirmation of Kingspan Insulation's products' Green Guide ratings. S ustainability & Responsibility Kingspan Insulation has a long term commitment to sustainability and responsibility: as a manufacturer and supplier of insulation products; as an employer; as a substantial landholder; and as a key member of its neighbouring communities. Specification Clause Kingspan Thermawall TW56 Insulated Plasterboard should be described in specifications as: The wall dry-lining insulation shall be Kingspan Thermawall TW56 Insulated Plasterboard mm thick: comprising a high performance rigid thermoset insulation core with 12.5 mm plasterboard bonded to its front surface and a low emissivity composite foil on its reverse surface. The product shall be manufactured: with a blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP); under a management system certified to BS / I.S. EN ISO 9001: 2008, BS / I.S. EN ISO 14001: 2004 and BS / I.S. OHSAS 18001: 2007; by Kingspan Insulation Limited; and installed in accordance with the instructions issued by them. Fixing Methods Kingspan Thermawall TW56 Insulated Plasterboard can be installed utilising mechanical fixing techniques only. Kingspan Thermawall TW52 Insulated Plasterboard should be used for dot and dab bonding using plaster, and proprietary adhesives. Design Standards BS 8212: 1995 (Code of practice for dry lining and partitioning using gypsum plasterboard) should be considered. Limitations Kingspan Thermawall TW56 Insulated Plasterboard has a gypsum plasterboard face. It should, therefore, not be used to isolate dampness, nor be used in continuously damp or humid conditions. Fire Stops Current Building Regulations / Standards should be considered with regard to the requirements for and provision of fire stops. Water Vapour Control / Condensation Consideration should be given to the risk of condensation, when designing thermal elements. When internally lining a construction with insulation, condensation can be controlled by ensuring there is a layer of high vapour resistance on the internal surface of the construction. Kingspan Thermawall TW56 Insulated Plasterboard contains an integral vapour control layer and, when installed correctly with appropriate detailing at joints between sheets, penetrations and wall perimeters, can provide the necessary vapour resistance. If required, the vapour resistance of the wall lining can be increased by the application of two coats of Gyproc Drywall Sealer. A condensation risk analysis should be carried out following the procedures set out in BS 5250: 2002 (Code of practice for the control of condensation in buildings). The Kingspan Insulation Technical Service Department (see rear cover) can provide this service. Typical U-values mm Brick Outer Leaf / Cavity / 100mm Block Inner Leaf U values (W/m 2. K) for Various Thicknesses of Kingspan Thermawall TW56 Insulated Plasterboard Clear Cavity Thickness (mm)* U value (W/m 2. K) mm cavity partially filled with 60mm of Kooltherm K8 Thickness (mm)* U value (W/m 2. K) *Product thickness = insulant thickness mm plasterboard. Calculations assume TW56 boards are mechanically fixed to treated timber battens. NB These are generic U-Values. Please contact Kingspan Insulation Technical Department for specific information. 2

3 Sitework Preperation The ceiling lining should be in position before wall lining commences. Wall mounted fittings such as electrical sockets should be fitted so as to take into account the additional wall thickness. On existing constructions all surfaces should be clean, dry and free of loose or flaking materials. Wallpaper should be stripped and surface mounted fittings removed. Mechanical Fixing To Timber Framing Studs / Battens This method may be used on timber frame constructions or on masonry walls that will support and retain battens and associated fixings. Vertical timber framing studs / battens should be set at maximum 600 mm horizontal centres, and timber framing studs / battens / noggins should be positioned horizontally at floor and ceiling level and at max mm vertical centres. If fixing to battens, they should be mechanically fixed to the wall, and comprise 25 x 47 mm (min.) treated softwood, backed with a strip of damp proof course (DPC). Where joints between sheets of insulated plasterboard are unsupported by the timber framing studs / battens, timber noggins should be installed. Each sheet of insulated plasterboard should lap timber framing studs / battens / noggins by 19 mm (min.) at sheet joints. Sheets of Kingspan Thermawall TW56 Insulated Plasterboard should be fixed using either drywall screws at 300 mm centres, or large headed galvanised clout nails at 150 mm centres. When installing sheets onto timber battens, fixings should be located no less than 10 mm from the edges of the sheets, and be long enough to allow minimum 22.5 mm penetration of the timber. Fixings should not penetrate through the battens. When installing sheets onto timber frame studs, fixings should be located no less than 10 mm from the edges of the sheets, and be long enough to allow a minimum 25 mm penetration of the timber. Fixings should be driven straight, with the heads embedded just below the surface of the plasterboard. Care should be taken not to overdrive nails / screws. To Metal Framing Systems Because metal framing systems are proprietary, sitework guidance should be sought from the framing system manufacturer. However, in the absence of any other guidance, the instructions laid out below may be followed. The metal framing should be installed as a separate structure, independent from the masonry or concrete wall, to provide a vertical and flat base for the sheets of insulated plasterboard. The framing should be set at a maximum of 600 mm centres to coincide with the long edges, and centre lines, of the sheets of insulated plasterboard. Short lengths of metal framing should be fixed horizontally between the vertical pieces at skirting level, just below the ceiling or soffit level, and at max mm vertical centres. Short lengths of metal framing should also be used as noggins where board joints between sheets are unsupported. Sheets of Kingspan Thermawall TW56 Insulated Plasterboard should be fixed using either drywall screws at 300 mm centres, or self drilling and tapping, countersunk, zinc coated screws placed at 150 mm centres. Fixings should be located no less than 10 mm from the edges of the sheet. Fixings should be driven straight, with the heads embedded just below the surface of the plasterboard. Care should be taken not to overdrive screws. Direct to Masonry Substrates This installation method is suitable for rendered or cavity walls. The wall should be sound, dry and flat (as surface irregularities may impede fixing of the board). The board should be fully restrained using mechanical fixings. The type and length of mechanical fixing required will depend on the type of masonry substrate and the the thickness of Kingspan Thermawall TW56 Insulated Plasterboard. For details on fixings refer to: Ejot UK Limited: +44 (0) HILTI: (RoI) / (NI) MAK Fasteners: +353 (0) Tech Fasteners: +353 (0) Fixings should not overlap board edges. 3

4 Sitework Fixing Heavy Internal Fittings To Timber Joists or Rafters Sheets of Kingspan Thermawall TW56 Insulated Plasterboard may be used to line ceilings (see Figure 1). Kingspan Kooltherm K7 Pitched Roof Board 3mmskimcoatedKingspan Thermawall TW56 Insulated Plasterboard under rafters Figure 1 Mechanically fixed to timber rafters with Kingspan Kooltherm K7 Pitched Roof Board between rafters Thermawall TW56 Insulated Plasterboard under rafters Sheets must always be placed with the long edge running across the joists or rafters, and all edges must be supported. Where joints between sheets of insulated plasterboard are unsupported by the timber joists / rafters, timber noggins should be installed. Each sheet of insulated plasterboard should lap joists / rafters / noggins by 19 mm (min.) at sheet joints. Sheets should be fixed using either drywall screws at 230 mm centres, or large headed galvanized clout nails placed at 150 mm centres. Fixings should be located no less than 10 mm from the edges of the sheet, and be long enough to allow a minimum 25 mm penetration of the timber. Fixings should be driven straight, with the heads embedded just below the surface of the plasterboard. Care should be taken not to overdrive nails / screws. Suitable mechanical fixings should be used for heavy internal fittings (kitchen units, shelving etc), to ensure the load is applied direct to the supporting wall and not to the Kingspan Thermawall TW56 Insulated Plasterboard For details on fixings refer to: Ejot UK Limited: +44 (0) HILTI: (RoI) / (NI) MAK Fasteners: +353 (0) Tech Fasteners: +353 (0) Alternatively, where there are to be extensive heavy internal fittings, the construction outlined in Figure 2 can be adopted. Figure 2 Masonry substrate 25 x 47 mm timber batten Strip of damp proof course (if there is a risk of moisture penetration) Kingspan Kooltherm K12 Framing Board 18 mm plywood 3mmskimcoated 12.5 mm plasterboard 5mmpacker(see Sitework Corner&SkirtingDetails ) Vertical timber framing studs / battens should be set at maximum 600 mm horizontal centres and timber framing studs / battens / noggins should be positioned horizontally at floor and ceiling level and at max mm vertical centres. If fixing to battens, they should be mechanically fixed to the wall, and comprise 25 x 47 mm (min.) treated softwood backed with a strip of damp proof course (DPC). Where insulation board joints are unsupported by the timber framing studs / battens, timber noggins should be installed. 4

5 Each insulation board should lap timber framing studs / battens / noggins by 19 mm (min.) at board joints. Boards of Kingspan Kooltherm K12 Framing Board should be temporarily fixed / nailed to timber framing studs / battens. 18 mm plywood should then be fixed through insulation boards to the timber framing studs / battens, using either drywall screws at 300 mm centres, or large headed galvanised clout nails at 150 mm centres. When fixing plywood through the insulation boards onto timber battens, fixings should be located no less than 10 mm from the edges of the sheets, and be long enough to allow minimum 22.5 mm penetration of the timber. Fixings should not penetrate through the battens. When fixing plywood through the insulation boards onto a timber frame, fixings should be located no less than 10 mm from the edges of the sheets, and be long enough to allow a minimum 25 mm penetration of the timber. Fixings should be driven straight, with the heads embedded just below the surface of the plywood mm plasterboard is then fixed to the plywood, using either drywall screws at 300 mm centres, or large headed galvanised clout nails at 150 mm centres. Fixings should be driven straight, with the heads embedded just below the surface of the plasterboard. Care should be taken not to overdrive nails / screws. Heavy fittings can be fixed through the plasterboard directly to the plywood. Corner & Skirting Details For internal and external corners, sheets should be cut and rebated to allow a plasterboard / plasterboard joint at the angle (see Figures 3 & 5). For internal and external corners, ensure sheets are lightly butted and air gaps minimised to reduce the risk of thermal bridging (see Figures 3 & 5). Figure 3 Internal corner detail Timber batten Kingspan Thermawall TW56 Insulated Plasterboard A 5 mm packer should be used at the base of the wall to provide a level surface from which to build up the boards. The packer should be replaced with a flexible urethane / acoustic sealant prior to skirting being fitted (see Figure 4). Kingspan Thermawall TW56 Insulated Plasterboard Skirting board Flexible sealant Figure 4 Packer and skirting detail 5

6 Sitework Window / Door Reveals & Soffit Details Fixing should employ the same method as is used for the plain wall areas. The use of a thinner sheet of Kingspan Thermawall TW56 Insulated Plasterboard at reveals may be necessary (see Figure 5). Kingspan Thermawall TW56 Insulated Plasterboard Figure 5 Insulated reveal and external corner Finishing Double glazed window unit To avoid air leakage, any penetrations through the insulation (electrical sockets, plumbing and wiring etc) should be sealed with vapour resistant mastic sealant. Any remaining gaps between boards / sheets of insulation should be filled with expanding urethane sealant. Tapered edged boards allow the employment of standard dry lining techniques. Plasterboard tape should be employed at all board joints, and a plaster skim finish applied. The skimming should be carried out in accordance with the specified plaster manufacturer s instructions, particularly in relation to the need to allow thorough drying of the plaster prior to decoration. Linear Thermal Bridging Window sill Linear thermal bridging describes the heat loss at junctions between elements, where the geometry of the junction means that a building s primary insulation layer is not continuous or is reduced. This heat loss is represented by the junction s Psi (ψ) value. The ψ values of all the linear thermal bridges in a building are used to calculate an overall Y value which is used in whole building carbon dioxide emissions calculation software. At a window or door opening, in a wall insulated with Kingspan Thermawall TW56 Insulated Plasterboard, the linear thermal bridge is the reveal. This linear thermal bridge can be reduced by insulating the reveal. The key factor is the thermal resistance (R value) of this insulation layer. Accredited Construction Details (England & Wales / Scotland / Northern Ireland) and Acceptable Construction Details (Republic of Ireland), collectively referred to here as ACDs, feature details for walls with insulated dry lining, with reveals insulated with a material of minimum thermal resistance (R value) of 0.34 m 2. K/W. These constructions have the following ψ values: 0.50 W/m.K for a steel lintel with a perforated steel base, 0.30 W/m. K for other lintels (including steel lintels), 0.04 W/m. K for a sill and 0.05 W/m. K for a jamb. Adhering to these constructions, entitles a designer to use a default Y value in whole building carbon dioxide emissions calculation software. ACDs are specifically targeted at new build constructions and, where applicable, they are also considered best practice for refurbishment. Reveals should be designed to accommodate a minimum 37.5 mm of Kingspan Thermawall TW56 Insulated Plasterboard required to achieve an R value of 0.34 m 2. K/W, and the depth of fixing system and finishings (see Sitework Figure 5). General Cutting Cutting should be carried out either by using a fine toothed saw, or by using a sharp knife to cut through the insulation and paper backing of the plasterboard, then snapping the sheet face down over a straight edge and cutting the paper facing of the plasterboard on the other side. Ensure accurate trimming to achieve close butting joints and continuity of insulation. Availability Kingspan Thermawall TW56 Insulated Plasterboard is available through specialist insulation distributors and selected builders merchants throughout the UK and Ireland. Packaging and Storage The polyethylene packaging of Kingspan Insulation products, which is recyclable, should not be considered adequate for outdoor protection. Ideally sheets should be stored inside a building. If, however, temporary outdoor storage cannot be avoided then the sheets should be stacked flat on a level base clear of the ground, and completely protected from inclement weather by use of an opaque polythene sheet or weatherproof tarpaulin. Sheets that have been allowed to get wet should not be used. Health and Safety Kingspan Insulation products are chemically inert and safe to use. A Safety Information Data Sheet for this product is available from the Kingspan Insulation website Warning do not stand on or otherwise support your weight on this product unless it is fully supported by a load bearing surface. 6

7 Product Details The Front Facings The front facing of Kingspan Thermawall TW56 Insulated Plasterboard is a tapered edge gypsum based plasterboard which readily accepts dry jointing materials and plaster skim. The Core The core of Kingspan Thermawall TW56 Insulated Plasterboard is a premium performance rigid thermoset modified resin insulant manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP). The Reverse Face The reverse facing of Kingspan Thermawall TW56 Insulated Plasterboard is low emissivity composite foil, autohesively bonded to the insulation core during manufacture. Standards and Approvals Kingspan Thermawall TW56 Insulated Plasterboard is manufactured to the highest standards under a management system certified to BS / I.S. EN ISO 9001: 2008 (Quality management systems. Requirements), BS / I.S. EN ISO 14001: 2004 (Environmental Management Systems. Requirements) and BS / I.S OHSAS 18001: 2007 (Health and Safety Management Systems. Requirements). The use of Kingspan Thermawall TW56 Insulated Plasterboard, produced at Kingspan Insulation s Castleblayney manufacturing facility, is covered by NSAI Agrément Certificate Standard Dimensions Kingspan Thermawall TW56 Insulated Plasterboard is available in the following standard size: Nominal Dimension Availability Length (m) 2.4 Width (m) 1.2 Plasterboard Thickness (mm) 12.5 Insulant Thickness (mm) Refer to local distributor or Kingspan Insulation price list for current stock and non stock sizes. Compressive Strength The compressive strength of Kingspan Thermawall TW56 Insulated Plasterboard typically exceeds 125 kpa at 10% compression, when tested to BS / I.S. EN 826: 1996 (Thermal insulating products for building applications. Determination of compression behaviour). Water Vapour Resistance Adjusted for the effect of board joints, non plasterboard component of the product typically achieves a resistance far greater than 100 MN.s/g, when tested in accordance with BS EN 12086: 1997 / I.S. EN 12086: 1998 (Thermal insulating products for building applications. Determination of water vapour transmission properties). For the purposes of calculation of condensation risk, the resistivity of the plasterboard component of the product should be taken as 50 MN.s/g.m Durability If correctly installed, Kingspan Thermawall TW56 Insulated Plasterboard can have an indefinite life. Its durability depends on the supporting structure and the conditions of its use. Resistance to Solvents, Fungi & Rodents The insulation core is resistant to short term contact with petrol and with most dilute acids, alkalis and mineral oils. However, it is recommended that any spills be cleaned off fully before the boards are installed. Ensure that safe methods of cleaning are used, as recommended by the suppliers of the spilt liquid. The insulation core is not resistant to some solvent based adhesive systems, particularly those containing methyl ethyl ketone. Adhesives containing such solvents should not be used in association with this product. Damaged boards or boards that have been in contact with harsh solvents or acids should not be used. The insulation core and facings used in the manufacture of Kingspan Thermawall TW56 Insulated Plasterboard resist attack by mould and microbial growth and do not provide any food value to vermin. 7

8 Product Details Fire Performance The boards will achieve the result given which enable them to be classified by the Building Regulations as being Class 0 rated and Low Risk by the Building Standards in Scotland. Test Result BS 476 6: 1989 Index of performance (1) not (Fire test on building materials exceeding 12 and sub Index and structures. Method of test (i 1 ) not exceeding 6 for fire propagation for products) BS 476-7:1997 (Fire tests on building materials and structures. Method of test to determine the classification of the surface spread of flame of products) Class 1 rating Further details of the fire performance of Kingspan Insulation products may be obtained from the Kingspan Insulation Technical Service Department (see rear cover). Thermal Properties The λ values and R values detailed below are quoted in accordance with BS / I.S. EN 13165: 2008 (Thermal insulation products for buildings Factory made rigid polyurethane foam (PUR) products Specification). Thermal Conductivity The thermal conductivity (λ value) of of the plasterboard component of Kingspan Thermawall TW56 Insulated Plasterboard is 0.19 W/m. K. The thermal conductivity (λ value) of the insulation core of Kingspan Thermawall TW56 Insulated Plasterboard is W/m. K. Thermal Resistance Thermal resistance (R value) varies with thickness and is calculated by dividing the thickness of the board (expressed in metres) by its thermal conductivity. The resulting number is rounded down to the nearest 0.05 (m 2. K/W). Product Thickness (mm)* Thermal Resistance (m 2. K/W) * Product thickness = insulation thickness mm plasterboard. NB Refer to local distributor or Kingspan Insulation price list for current stock and non stock sizes. 8

9 Kingspan Insulation Insulation Product Benefits Kingspan Kooltherm K range Products With a thermal conductivity of W/m. K these are the most thermally efficient insulation products commonly used. The thinnest commonly used insulation products for any specific U value. Rigid thermoset insulation core is Class 0, as defined by the Building Regulations in England, Wales & Ireland, and Low Risk as defined by the Building Standards in Scotland. Rigid thermoset insulation core achieves the best possible rating of < 5% smoke obscuration when tested to BS 5111: Part 1: Manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP). Kingspan Therma Range Products With a thermal conductivity of W/m. K these are amongst the more thermally efficient insulation products commonly used. Kingspan Aero With a thermal conductivity of W/m.K, these products offer high performance in a range of standard applications. Each product achieves the required fire performance for its intended application. Manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP). All Products Their closed cell structure resists both moisture and water vapour ingress a problem which can be associated with open cell materials such as mineral fibre and which can result in reduced thermal performance. Unaffected by air infiltration a problem that can be experienced with mineral fibre and which can reduce thermal performance. Safe and easy to install non fibrous. If installed correctly, can provide reliable long term thermal performance over the lifetime of the building. Each product achieves the required fire performance for its intended application. Manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP). Kingspan Styrozone Range Products Rigid extruded polystyrene insulation (XPS) has the necessary compressive strength to make it the product of choice for specialist applications such as heavy duty flooring, car park decks and inverted roofing. Each product achieves the required fire performance for its intended application. Manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP). 9

10 Contact Details Customer Service For quotations, order placement, details of despatches and general enquiries. Tel: +353 (0) Fax: +353 (0) Technical Advice / Design Kingspan Insulation supports all of its products with a comprehensive Technical Advisory Service for specifiers, stockists and contractors. Tel: +353 (0) Fax: +353 (0) technical@kingspaninsulation.ie Kingspan Insulation Ltd Castleblayney, County Monaghan, Ireland Pembridge, Leominster, Herefordshire HR6 9LA, UK Kingspan, KoolDuct, Kooltherm, nilvent, Styrozone, TEK, the oz Device and the Lion Device are Registered Trademarks of the Kingspan Group plc in the UK, Ireland and other countries. All rights reserved. Therma is a Trademark of the Kingspan Group plc. Registered in England & Wales, No Registered Office: Pembridge, Leominster, Herefordshire HR6 9LA, UK. VAT GB Registered in Ireland, No Registered Office: Bree Industrial Estate, Castleblayney, Co. Monaghan, Ireland. VAT IE J.